What's happening at Control-Care...

For each compressor, natural gas, syngas, ammonia refrigeration, air and CO₂ respectively, a dedicated fault tolerant PLC type controller with purposely built control applications was commissioned. In addition, control for 6 steam turbines for Syngas/Refrigerant/Air/CO2 compressors, Generator and boiler feedwater pump were part of the scope as well. Three of these steam turbines also have extraction control enabled.  The scope of this project was limited only to speed control for the turbines and anti-surge control for the compressors, but was a technical challenge in relation to the tight margins for the extraction control pressure. 

Control-Care is providing engineering and  site services, including field commissioning in 2022, support.  This includes the development, support, and maintenance of the process controls and the instrumented protection functions, with the objective of ensuring a safe, reliable, environmentally sound, optimized, and energy-efficient day to day operation. Also including keeping up to date the related controlled documents: Process Control Narratives (PCN), Instrument Safeguarding Narratives (ISN), and Cause and Effect matrices.

Control-Care has implemented an integrated compressor control system on an ABB DCS. The steam turbine drive, for one of the two blowers working in parallel, has been replaced by an ABB electrical drive, using the AC800M controller. Control-Care scope was defined to optimize blower operation by replacing existing turbomachinery control to an integrated solution on ABB's AC800M controller. Commissioning and startup of this electrification project was delayed due to Covid situation but has now been successfully completed.

Control-Care has provided site services including field commissioning support for greenfield delivery an OEM produced steam turbine generator set to Germany. In this plant, sewage waste is incinerated and thermal energy is supplied to the city's district heating. The steam generated by sludge combustion is also used to generate electricity. Control-Care acted as site supervisor and responsibilities included successfull commissioning of the steam turbine and generator. Click on the picture for further details.

Control-Care has provided site installation and field commissioning support for the delivery of two OEM produced gasturbine compressor set to Latin America. Full site support services were provided for the installation of gasturbine, compressor, mechanical machinery alignment, coolers, lube oil system, ventilators, silencers, turbine air intake, valves and compressor nozzles. Project was original posted in February 2020 and second unit was recently completed. Click on the picture for further details.

From a compressor control optimalization study performed in 2019 by Control-Care, to project execution phase in 2021 for an FPSO located in the United Kingdom. Involved in this study and execution phase were two variable speed centrifugal compressors used for oil gas separation installed on board.  Essential control system modifications were made to the 25+ year old control philosophy and PLC system for both compressors to improve operability of the units, increase production and to reduce downtime of the units due to unexpected process trips.  The new control strategy was flawlessly implemented offshore following a thorough (remote) FAT using the end user’s spare controllers with end user’s PLC software staged in Control-Care’s premises.  

Control-Care has successfully provided augmented reality (AR) remote assistance services for calibration, troubleshooting and testing of the main steam control valves on two 150MW steam turbine generator (STG) units for AboitizPower subsidiary Therma South, Inc. in Davao, Philippines. Due to covid travel restrictions our engineers could not be present on site. This remote assistance solution has enabled the end-user to still carry out the required activities effectively and accurately, without jeopardizing the turn-around schedule. The end-user’s engineer was carrying the AR remote assistance tool, whilst the Control-Care expert was monitoring and providing instructions from the headquarters in The Netherlands. The AR remote assistance tool is suitable for harsh industrial environments and ensures a safe working environment since it enables the user to still operate “hands-free”.

Control-Care successfully supported an Independent Service Provider ("ISP") during a minor steam turbine inspection / maintenance. Control-Care's specialist(s) were assigned, via an independent service provider (mechanical), to the turnaround team during a scheduled minor inspection. The scope included removal, cleaning & inspection of mechanical parts of the turbines. Installation and adjustment of all instrumentation, valves and controls, re-assembly of all mechanical equipment and start up.  Control-Care's support activities also included operational support after unit start up.

Control-Care successfully supported an Independent Service Provider ("ISP") during a scheduled turnaround. Control-Care's specialist(s) were assigned, via an independent service provider (mechanical), to the turnaround team during a major nitrogen compressor overhaul. Turnaround services included (dis)connecting of E-Motor, IGV's and PCV&ACV, oilpump(s) and other transmitters such as pressure and temperature transmitters on coolers and compressor. The work was performed under supervision and direction of the independent service provider and included troubleshooting,  system I/O checks and loop checks, software functional and interlock testing and to provide operational support as the plant was re-started for production.

Comprehensive scope of field services delivered by Control-Care’s engineer for compressors on a gas processing plant.  Executed work involved review and analysis of operating values in accordance with trends and process gas compressor unit event logs. Functional check of alarm, protection system, surge control system, operation of control valves. Required sensors and cables of gas compressor unit were demounted and re-installed together with the local mechanical engineer. Functionality of oil supply system was checked and documented. The project was finalized after commissioning of the control system and support during compressor start up.

Control-Care successfully supported the compressor OEM with I&C works in preparation for a FAT of a three-stage centrifugal compressor on an FPSO. The FPSO, currently under construction, will be capable of processing 90,000 barrels of crude oil per day, 75 million cubic feet of gas per day, 120,000 barrels of water injection per day and have a storage capacity of 900,000 barrels of crude oil. The scope for the OEM included the testing and support services for Inconel 625 cladding of casing and covers, Fix Speed Electrical Motor, Gear Box, Lube Oil System, Couplings for HS and LS shaft, Seal Gas Panel, Unit Control Panel (UCP), Anti-Surge Control Valves and Suction Throttling Valves.

Control-Care's DCS specialist(s) were seconded, via the main automation contractor, to the end user's project team during a major DCS control system hardware and software upgrade. The DCS control system's main hardware was upgraded. The PC based operator and engineering workstations were upgraded to a server and thin client architecture. The work was performed under supervision and direction of the main automation contractor and included firmware downloads, software patches and modifications, control system configuration and troubleshooting,  system I/O checks and loop checks, software functional and interlock testing and to provide operational support as the plant was re-started for production.

Trouble shooting and diagnose fuel metering valves used on gasturbine(s) after oxidation problems had been reported. Inspect the current set-up, advise root cause and advise on preventive actions e.g. inspection of the installation, proper installation and support, correct installation of the vent line(s), properly sized power cables of the correct wire gauge for the length of the cable, etc. Provided services included recommendations on periodic maintenance activities and software changes.

Project management, engineering, documentation and hardware delivery for the replacement of the existing surge detection system for an axial air compressor and an NOx compressor. The existing software functionality will be transferred to the new safety PLC using Control-Care's SPA Surge Protection Application , which will run on a triple redundant Safety PLC, and as independent tasks in a two out of three-selection scenario. Existing and dedicated transmitters surge protection transmitters will be replaced by new temperature and pressure transmitters. Selected platform and software tasks are Control-Care's Compressor SPA Surge Protection Application on a triple redundant Rockwell Automation's Compact GuardLogix PLC. 

Voor de eindgebruiker is het een groot voordeel dat deze regelingen niet langer dure en specialistische systemen hoeven te zijn maar dat deze in een PLC geïntegreerd kunnen worden welke ook voor procesregeling gebruikt kan worden. Control-Care is gespecialiseerd in compressor antisurge- en stoomturbineregelingen en heeft in samenwerking met De Gidts & Feldman hun jarenlange ervaring gebruikt bij het ontwikkelen van speciale functieblokken voor de Honeywell ControlEdge PLC, waarin speciale regelalgoritmes zijn geïntegreerd. Lees het volledige artikel gepubliceerd in processcontrol editie oktober 2020.

Control-Care completed and realized an integrated compressor control and protection system on a plant DCS which was sold in 2019. A greenfield project adding a new depletion gas compressor to an existing exploration site in New Zealand. Customer quote: "We are very pleased about the functionality of both ACA & PCA applications as well as the professionalism & technical capability that Engineer A & B demonstrated throughout the cold and hot commissioning phases. From project side I am also very pleased about the overall quality and tidiness of supplied deliverables, control system configuration and MOC procedure applied. In general, a very well executed job despite the COVID challenge." 

With the rapid advancement of microprocessor technology, there is a shift in process control and turbomachinery control towards a software-based solution. When replacing or upgrading (obsolete) turbomachinery control systems, integrating process automations systems for turbomachinery controls provides multiple benefits. It increases the reliability of a customer’s machinery and process. Read the full article.

Control-Care provided an interactive training course to a team of engineers at Chemelot park in Geleen. Dynamic compressor simulation was used to demonstrate compressor behaviour, surge detection and compressor control applications. Sharing turbomachinery controls knowledge and insights directly to the team enabled the engineers to apply insights to their own practices.

Control-Care has received the order for a steam turbine controls integration into the plant’s DCS. This is the second order from this refinery in the Netherlands after successful implementation of the first steam turbine control system into the plant’s DCS. In Control-Care scope is supply is project software engineering of the control system application including HMI screens and application configuration. Commissioning and Startup is scheduled for later this year.

Control-Care has upgraded the control and protection system of the second Mitsui steam turbine driving a large fan (blower) on one of the largest phosphate mining and processing plant in Morocco. Our scope of delivery includes the unit control panel with our Steam Turbine Control Application (STCA) in a redundant PLC, overspeed protection device, governor valve actuators and trip valve actuator and speed sensors. This is the second unit after the first was done back in 2018.

Control-Care has provided site installation and field commissioning support for the delivery of a OEM produced gasturbine compressor set to Latin America. Full site support services were provided for the installation of gasturbine, compressor, mechanical machinery alignment, coolers, lube oil system, ventilators, silencers, turbine air intake, valves and compressor nozzles.